Shelf bracket and method of making same

ABSTRACT

A shelf bracket having a ledge and a plurality of side members, the shelf bracket being formed from a blank. The blank has a plurality of side portions, which can be bent downwardly to create the side members. The blank also has a ledge portion which forms the ledge of the shelf bracket. The side portions and the ledge portion of the blank are separated by a plurality of bend lines, to facilitate bending for the formation of the shelfbracket. The blank desirably has a lip portion which can be bent upwardly to form a lip of the shelf bracket. The blank can also have a plurality of stiffener portions which can be bent to create stiffeners in the shelf bracket, and one or more ribs in the side portions to provide strength to the shelf bracket.

CROSS REFERENCE TO RELATED APPLICATIONS

The present application claims priority to the provisional patentapplication identified by U.S. Ser. No. 60/643,939, filed on Jan. 14,2005, the entire content of which is hereby incorporated herein byreference.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT NotApplicable BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

FIG. 1 is a perspective view of a shelf bracket, constructed inaccordance with the present invention, connected to a support.

FIG. 2 is a perspective view of the shelf bracket depicted in FIG. 1.

FIG. 3 is another perspective view of the shelf bracket depicted in FIG.1, showing an underside of the shelf bracket.

FIG. 4 is a top plan view of a blank utilized for forming the shelfbracket depicted in FIG. 1.

FIG. 5 is a perspective view of another shelf bracket constructed inaccordance with the present invention having one or more rib formed inside members to provide the shelf bracket with additional strength.

FIG. 6 is a perspective view of the shelf bracket of FIG. 5.

FIG. 7 is another perspective view of the shelf bracket of FIG. 5,showing an underside of the shelf bracket.

FIG. 8 is a top plan view of a blank utilized for forming the shelfbracket depicted in FIG. 5.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT OF THE INVENTION

Referring now to the drawings, and in particular to FIGS. 1-2, showntherein and designated by a reference numeral 10 is a shelf bracketconstructed in accordance with the present invention. The shelf bracket10 is connected to a support 12 (shown in FIG. 1) such that a ledge 14of the shelf bracket 10 is capable of supporting a load 16 (shown inFIG. 1). The support 12 can be any type of post, or vertical supportcapable of supporting the shelf bracket 10. For example, the support 12can be a 2×4 stud utilized commonly in the building constructionindustry, particularly in barns and sheds where additional storagecapacity is desirable. The load 16 can be anything capable of beingsupported by the shelf bracket 10. For example, it is envisioned thatmore than one of the shelf bracket 10 will be utilized for forming ashelving unit (not shown). In this case, at least two of the shelfbrackets 10 would be utilized with the shelf brackets 10 being spaced adistance laterally apart. In this instance, the load 16 will commonlyinclude a shelf which is positioned upon the ledges 14 upon which othertypes of loads, such as paint cans, coolers, books, or the like will bestored.

The shelfbracket 10 is also provided with a lip 20, and a pair of sidemembers 21 and 22. The ledge 14 is provided with a first end 24, asecond end 26, a first side 28, and a second side 30. The lip 20 isconnected to the second end 26 of the ledge 14, and extends a distancetherefrom. The lip 20 is preferably separated from the ledge 14 via abend line 32 extending between the lip 20 and the ledge 14. The sidemember 21 is connected to the first side 28 of the ledge 14, and extendsa distance downwardly therefrom generally at an angle of about 90°. In asimilar manner, the side member 22 is connected to the second side 30 ofthe ledge 14 and also extends downwardly therefrom at an angle of about90°. The side member 21, and the side member 22 are separated from theledge 14 via bend lines 34 and 36. The bend lines 32, 34 and 36 formweakened linear areas within the shelf bracket 10 and can be formed byany suitable method, such as a series of round holes, a series of slots,or a laser cutline. Shown by way of example in FIG. 1 are the bend lines32, 34 and 36 being formed from a series of slots.

The side members 21 and 22 extend past the first end 24 of the ledge 14so as to form a cavity into which the support 12 is positioned. Thefirst end 24 of the ledge 14 engages the support 12 when the shelfbracket 10 is installed on the support 12, and the side members 21 and22 wrap around the support 12 so that the side members 21 and 22 canengage the support 12. For example, as shown in FIG. 1, the side members21 and 22 can be connected to the support 12 by a plurality of fasteners38 (the fasteners 38 are designated as 38 a, 38 b and 38 c for purposesof clarity) positioned through a plurality of openings 40 (the openings40 are designated as 40 a, 40 b and 40 c for purposes of clarity) andsecured to the support 12.

To stabilize the shelf bracket 10 on the support 12, the shelfbracket 10is provided with a pair of stiffeners 42 (shown in FIG. 3) and 43. Thestiffeners 42 and 43 are connected to and extend inwardly from the sidemembers 21 and 22. The stiffeners 42 and 43 are preferably separatedfrom the side members 21 and 22 via bend lines 44 and 45 extendingbetween the stiffeners 42 and 43 and the side members 21 and 22. Thestiffeners 42 and 43 engage the support 12 to prevent downward rotationof the shelf bracket 10 on the support 12. The stiffeners 42 and 43 arealigned with the first end 24 of the ledge 14 so that when thestiffeners 42 and 43, and first end 24 of the ledge 14 are positionedagainst the support 12 the ledge 14 extends generally 90° away from thesupport 12.

To secure the load 16 on the ledge 14, the shelf bracket 10 can beprovided with any suitable assembly. For example, the shelf bracket 10can be provided with openings 46 and 48 extending through the ledge 14so that a fastener, such as a screw can be inserted through the openings46 and 48 and secured to the load 16.

Referring now to FIG. 4, shown therein is a blank 60 which can beutilized for forming the shelf bracket 10. The blank 60 is preferablyconstructed of a single sheet of material. The thickness, and/orconstruction of the material will vary based upon the desired use of theshelf bracket 10. For example, where the shelf bracket 10 will beutilized at an individual's home for supporting rather small loads 16,such as paint cans, the blank 60 can be constructed of a material suchas 18-22 gauge steel.

The blank 60 is provided with a substantially triangular shape. However,it should be understood that the blank 60 can be provided with any shapeso long as the blank 60 can be utilized as described herein. The blank60 defines a first side portion 62, a second side portion 64, a ledgeportion 66, a lip portion 68, a first stiffener portion 70, and a secondstiffener portion 72.

The ledge portion 66 is provided with a first end 76, a second end 78, afirst side 80, and a second side 82. The first side portion 62 bordersthe first side 80 of the ledge portion 66, and is separated therefrom byway of a bend line 86. The second side portion 64 borders the secondside 82 of the ledge portion 66 and is separated therefrom by way of abend line 88. The lip portion 68 borders the second end 78 of the ledgeportion 66 and is separated therefrom by way of a bend line 90. Thefirst stiffener portion 70 borders an outer side of the first sideportion 62 and is separated therefrom by way of a bend line 92. Thesecond stiffener portion 72 borders an outer side of the second sideportion 64 and is separated therefrom by way of a bend line 94. The bendlines 86, 88, 90, 92 and 94 can be formed from any suitable process forweakening the blank 60 in these areas. For example, the bend lines 86,88, 90, 92 and 94 can be formed by a series of circular cut outs, slots,or laser cutline.

The blank 60 can be formed from any suitable process. For example, theblank 60 can be formed by stamping, laser cutting, water jet cutting, orthe like.

To form the shelf bracket 10 from the blank 60, the first side portion62, and the second side portion 64 are bent approximately 90° withrespect to the ledge portion 66 so that the first side portion 62 formsthe side member 21, and the second side portion 64 forms the side member22. The ledge portion 66 of the blank 60 forms the ledge 14 of the shelfbracket 10.

To prevent the load 16 from falling off of the ledge 14, the lip portion68 can be bent upwardly, in a direction generally opposite the directionin which the first side portion 62 and the second side portion 64 havebeen bent. Additionally, the first stiffener portion 70, and the secondstiffener portion 72 can be bent inwardly to form the stiffeners 42 and43 depicted in FIG. 3.

It should be understood that the blank 60 is designed to be bent intothe shelf bracket 10 by an individual using tools normally owned by ahomeowner. Thus, it should be understood that the blank 60 can be bentusing either the hands of the individual, a small hand-operated tool,such as a pair of pliers or a hammer, or perhaps a homeowner's shopvise.

Referring now to FIGS. 5-8, shown therein and designated by a referencenumeral 10 a is another version of a shelf bracket constructed inaccordance with the present invention. The shelf bracket 10 a is similarin construction and function to the shelf bracket 10 described abovewith reference to FIGS. 1-4 respectively. The common features betweenthe shelf bracket 10 a and the shelf bracket 10 will not be describedhereinafter for purposes of brevity. However, the common features willbe labeled in FIGS. 5-8 with the same numeric prefix followed by an “a”alphabetic suffix.

The shelf bracket 10 a is provided with a pair of side members 21 a and22 a having at least one rib 50 formed in each of the side members 21 aand 22 a. The ribs 50 provide additional strength to the side members 21a and 22 a so that a thinner material can be used in forming the sidemembers 21 a and 22 a. Although only one rib 50 is shown in each of theside members 21 a and 22 a, it should be understood that more than onerib 50 can be provided in each of the side members 21 a and 22 a toprovide for even additional strength. The more than one rib 50 in eachof the side members 21 a and 22 a can be either spaced apart, orcontiguous.

Although the rib 50 is shown as extending generally across the entireside member 21 a, it should be understood that the rib 50 can extendonly partially across the side member 21 a. Further, multiple ribs 50can be positioned in certain areas of the side members 21 a so as toincrease the strength in such areas, while other areas of the sidemembers 21 a could be devoid of such ribs 50.

Furthermore, although the ribs 50 are shown as extending generallyparallel to the ledge portion of the shelf bracket 10 a, it should beunderstood that the ribs 50 can extend at any desirable angle ororientation with respect to the ledge portion of the shelf bracket 10 a.

The ribs 50 desirable form a “u” or a “v” cross-sectional shape on theside members 21 a and 22 a of the shelfbracket 10. However, it should beunderstood that the rib 50 may have any shape and be in any location onthe shelf bracket 10.

Referring now to FIG. 4, shown therein is a blank 60 a which can beutilized for forming the shelf bracket 10 a. The blank 60 a ispreferably constructed of a single sheet of material. The thickness,and/or construction of the material will vary based upon the desired useof the shelf bracket 10 a. For example, where the shelf bracket 10 willbe utilized at an individual's home for supporting rather small loads16, such as paint cans, the blank 60 a can be constructed of a materialsuch as 18-30 gauge steel or other light gauge material.

The blank 60 a is provided with a substantially triangular shape.However, it should be understood that the blank 60 a can be providedwith any shape so long as the blank 60 a can be utilized as describedherein. The blank 60 a defines a first side portion 62 a, a second sideportion 64 a, a ledge portion 66 a, a lip portion 68 a, a firststiffener portion 70 a, and a second stiffener portion 72 a.

The ledge portion 66 a is provided with a first end 76 a, a second end78 a, a first side 80 a, and a second side 82 a. The first side portion62 a borders the first side 80 a of the ledge portion 66 a, and isseparated therefrom by way of a bend line 86 a. The second side portion64 a borders the second side 82 a of the ledge portion 66 a and isseparated therefrom by way of a bend line 88 a. The lip portion 68 aborders the second end 78 a of the ledge portion 66 a and is separatedtherefrom by way of a bend line 90 a. The first stiffener portion 70 aborders an outer side of the first side portion 62 a and is separatedtherefrom by way of a bend line 92 a. The second stiffener portion 72 aborders an outer side of the second side portion 64 a and is separatedtherefrom by way of a bend line 94 a. The bend lines 86 a, 88 a, 90 a,92 a and 94 a can be formed from any suitable process for weakening theblank 60 a in these areas. For example, the bend lines 86 a, 88 a, 90 a,92 a and 94 a can be formed by a series of circular cut outs, slots, orlaser cutline(s).

The blank 60 a is also provided with at least two rib portions 100 whichform the ribs 50 when the blank 60 a is formed into the shelf bracket 10a. Each of the rib portions 100 extending across or inside one the firstside portion 62 a, or the second side portion 64 a. The rib portions 100provide additional strength to the side members 21 a and 22 a when theblank 60 a is formed into the shelf bracket 10 a so that a thinnermaterial can be used in forming blank 60 a. This reduces the cost of theblank 60 a. Although only one rib portion 100 is shown in each of theside portions 62 a and 64 a, it should be understood that more than onerib portion 100 can be provided in each of the side portions 62 a and 64a to provide for even additional strength. The more than one rib portion100 in each of the side portions 62 a and 64 a can be either spacedapart, or contiguous.

The blank 60 a can be formed from any suitable process. For example, theblank 60 a can be formed by stamping, laser cutting, waterjet cutting,extrusion, molding or the like. The rib portion 100 can be formed by anysuitable method, such as embossing, or stamping or the like.

It should be understood that the figures are not necessarily to scaleand certain features and certain views of the figures may be shownexaggerated in scale or in schematic in the interest of clarity andconciseness. It will also be understood from the foregoing descriptionthat various modifications and changes may be made in the presentinvention without departing from its true spirit.

This description is intended for purposes of illustration only andshould not be construed in a limiting sense. The scope of this inventionshould be determined only by the language of the claims that follow. Theterm “comprising” within the claims is intended to mean “including atleast” such that the recited listing of elements in a claim are an opengroup. “A,” “an,” and other singular terms are intended to include theplural forms thereof unless specifically excluded.

1. A blank for forming a shelf bracket having a ledge and a plurality ofside members, the blank constructed from a sheet of material comprising:a ledge portion having a first end and a second end; a plurality of sideportions extending past the first end of the ledge portion to form acavity to receive a support; and a plurality of bend lines separatingthe ledge portion and the plurality of side portions, the bend linesforming weakened areas within the blank; whereby each of the pluralityof side members of the shelf bracket is formed by moving one of theplurality of side portions of the blank downwardly from the ledgeportion of the blank, and the ledge of the shelfbracket is formed by theledge portion of the blank.
 2. The blank of claim 1, further comprising:a lip portion extending from the second end of the ledge portion; and abend line separating the ledge portion and the lip portion; whereby alip of the shelf bracket is formed by moving the lip portion of theblank upwardly from the ledge portion of the blank.
 3. The blank ofclaim 1, further comprising: a plurality of stiffener portions extendingfrom the side portions; and a plurality of bend lines separating theplurality of stiffener portions and the plurality of side portions;whereby each of a plurality of stiffeners of the shelf bracket is formedby moving one of the plurality of stiffener portions of the blankdownwardly from one of the plurality of side portions of the blank. 4.The blank of claim 1, wherein the shelf bracket further has a lip and aplurality of stiffeners, the blank further comprising: a lip portion; aplurality of stiffener portions; a bend line separating the lip portionand the ledge portion; and a plurality of bend lines separating theplurality of stiffener portions and the plurality of side portions;whereby the lip of the shelf bracket is formed by moving the lip portionof the blank upwardly from the ledge portion of the blank, and each ofthe plurality of stiffeners of the shelf bracket is formed by moving oneof the plurality of stiffener portions of the blank downwardly from oneof the plurality of side portions of the blank.
 5. The blank of claim 1,wherein the plurality of side portions of the blank has a plurality ofopenings such that the plurality of side members of the shelf bracketcan be secured to the support.
 6. The blank of claim 1, wherein theledge portion of the blank has a plurality of openings, such that a loadcan be secured to the ledge of the shelf bracket.
 7. The blank of claim1, further comprising a plurality of ribs with at least one ribpositioned in each of the side portions.
 8. A method of forming a shelfbracket having a ledge and a plurality of side members, the methodcomprising the steps of: providing a blank constructed from a sheet ofmaterial comprising a ledge portion having a first end and a second end,and a plurality of side portions extending past the first end of theledge portion to form a cavity to receive a support, separated by aplurality of bend lines forming weakened linear areas within the blank;and moving each of the plurality of side portions downwardly from theledge portion of the blank to form the plurality of side members of theshelf bracket; wherein the ledge portion of the blank forms the ledge ofthe shelf bracket.
 9. The method of claim 8, wherein the blank furthercomprises a lip portion extending from the second end of the ledgeportion and separated from the ledge portion by a bend line, the methodfurther comprising the step of: moving the lip portion of the blankupwardly from the ledge portion of the blank to form a lip of the shelfbracket.
 10. The method of claim 8, wherein the blank further comprisesa plurality of stiffener portions extending from the side portions andseparated from the plurality of side portions by a plurality of bendlines, the method further comprising the step of: moving each of theplurality of stiffener portions of the blank downwardly from theplurality of side portions of the blank to form one of a plurality ofstiffeners of the shelf bracket.
 11. The method of claim 8, wherein theblank further comprises a lip portion extending from the second end fothe ledge portion and separated from the ledge portion by a bend line,and a plurality of stiffener portions extending from the side portionsand separated from the plurality of side portions by a plurality of bendlines, the method further comprising the steps of: moving the lipportion of the blank upwardly from the ledge portion of the blank toform a lip of the shelf bracket; and moving each of the plurality ofstiffener portions of the blank downwardly from the plurality of sideportions of the blank to form one of a plurality of stiffeners of theshelf bracket.
 12. A method for forming a blank for use in forming ashelf bracket, the method comprising the steps of: providing a piece ofmaterial having a ledge portion with a first end and a second end, and aplurality of side portions extending past the first end of the ledgeportion to form a cavity to receive a support; and forming a pluralityof bend lines in the piece of material to separate a ledge portion and aplurality of side portions, the bend lines forming weakened linear areaswithin the piece of material; whereby the shelf bracket can be formed bymoving each of the plurality of side portions of the blank downwardlyfrom the ledge portion of the blank to form each of a plurality of sidemembers of the shelf bracket and the ledge portion of the blank forms aledge of the shelf bracket.
 13. The method of claim 12, furthercomprising the step of: forming a bend line in the piece of material toseparate the ledge portion and a lip portion which extends from thesecond end of the ledge portion; whereby a lip of the shelf bracket canbe formed by moving the lip portion of the blank upwardly from the ledgeportion of the blank.
 14. The method of claim 12, further comprising thestep of: forming a plurality of bend lines in the piece of material toseparate the plurality of side portions and a plurality of stiffenerportions which extend from the side portions; whereby stiffeners of theshelf bracket can be formed by moving the plurality of stiffenerportions of the blank downwardly from the plurality of side portions ofthe blank.
 15. The method of claim 12, further comprising the steps of:forming a bend line in the piece of material to separate the ledgeportion and a lip portion which extends from the second end of the ledgeportion; forming a plurality of bend lines in the piece of material toseparate the plurality of side portions and a plurality of stiffenerportions which extend from the side portions; whereby a lip of the shelfbracket can be formed by moving the lip portion of the blank upwardlyfrom the ledge portion of the blank, and a plurality of stiffeners ofthe shelf bracket, can be formed by moving the plurality of stiffenerportions of the blank downwardly from the plurality of side portions ofthe blank.